Storage and retrieval system

ABSTRACT

A storage array in an automated storage and retrieval system includes storage spaces arrayed on racks along picking aisles, multiple level decks, where at least one deck communicates with each aisle, where the decks and aisles are configured to define a rolling surface for an autonomous transport vehicle at each level of the decks, racks along at least one aisle at each level are at multiple rack levels that are accessed from a respective rolling surface that is common to the multiple rack levels, and a vertical pitch between rack levels varies for a portion of a respective aisle, the vertical pitch between at least two rack levels of the portion of the respective aisle is related to another vertical pitch between at least two other rack levels of another aisle portion of the respective aisle so the vehicle effects multiple picks in ordered sequence in a common aisle pass.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/890,088, filed on Feb. 6, 2018 (now U.S. Pat. No. 10,562,705), whichis a continuation of U.S. patent application Ser. No. 14/966,978, filedDec. 11, 2015 (now U.S. Pat. No. 9,884,719, issued Feb. 6, 2018), whichclaims priority from and the benefit of U.S. Provisional PatentApplication No. 62/091,162, filed on Dec. 12, 2014, the disclosures ofwhich are incorporated by reference herein in their entireties.

BACKGROUND 1. Field

The exemplary embodiments generally relate to material handling systemsand, more particularly, to transport and storage of items within thematerial handling system.

2. Brief Description of Related Developments

Multilevel storage and retrieval systems may be used in warehouses forthe storage and retrieval of goods. Generally the transportation ofgoods into and out of the storage structure is done with lifts fortransfer to a vehicle on a storage level, vehicles travelling up rampsto a predetermined storage level, or with vehicles that include liftstraveling along guide ways. Goods stored within the storage andretrieval system are generally stored in storage spaces on each storagelevel such that a transport vehicle disposed on that level has access toone level of storage spaces. In some instances goods stored in thestorage spaces do not occupy the entire storage space allocated to thegoods which results in inefficient use of the storage space.

It would be advantageous to increase storage density within a storageand retrieval system.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and other features of the disclosed embodiment areexplained in the following description, taken in connection with theaccompanying drawings, wherein:

FIG. 1 is a schematic illustration of an automated storage and retrievalsystem in accordance with aspects of the disclosed embodiment;

FIGS. 1A and 1B are schematic illustrations of portions of the automatedstorage and retrieval system in accordance with aspects of the disclosedembodiment;

FIG. 1C is a schematic illustration of the storage and retrieval systemin accordance with aspects of the disclosed embodiment;

FIG. 1D is a schematic illustration of a mixed pallet load formed by thestorage and retrieval system in accordance with aspects of the disclosedembodiment;

FIGS. 1E and 1F are schematic illustrations of portions of the storageand retrieval system in accordance with aspects of the disclosedembodiment;

FIG. 2 is a schematic illustration of a transport vehicle in accordancewith aspects of the disclosed embodiment;

FIG. 3 is a schematic illustration of a portion of the storage andretrieval system in accordance with aspects of the disclosed embodiment;

FIGS. 4-9 are schematic illustrations of portions of the transportvehicle in accordance with aspects of the disclosed embodiment;

FIG. 10 is a schematic illustration of a portion of the storage andretrieval system in accordance with aspects of the disclosed embodiment;

FIGS. 11-14 are exemplary flow diagrams in accordance with aspects ofthe disclosed embodiment;

FIG. 15 is a schematic illustration of an operator station of thestorage and retrieval system in accordance with aspects of the disclosedembodiment; and

FIG. 16 is an exemplary flow diagram in accordance with aspects of thedisclosed embodiment.

DETAILED DESCRIPTION

FIG. 1 is a schematic illustration of an automated storage and retrievalsystem 100 in accordance with aspects of the disclosed embodiment.Although the aspects of the disclosed embodiment will be described withreference to the drawings, it should be understood that the aspects ofthe disclosed embodiment can be embodied in many forms. In addition, anysuitable size, shape or type of elements or materials could be used.

In accordance with aspects of the disclosed embodiment the automatedstorage and retrieval system 100 may operate in a retail distributioncenter or warehouse to, for example, fulfill orders received from retailstores for case units such as those described in U.S. patent applicationSer. No. 13/326,674 filed on Dec. 15, 2011, the disclosure of which isincorporated by reference herein in its entirety. For example, the caseunits are cases or units of goods not stored in trays, on totes or onpallets (e.g. uncontained). In other examples, the case units are casesor units of goods that are contained in any suitable manner such as intrays, on totes or on pallets. In still other examples, the case unitsare a combination of uncontained and contained items. It is noted thatthe case units, for example, include cased units of goods (e.g. case ofsoup cans, boxes of cereal, etc.) or individual goods that are adaptedto be taken off of or placed on a pallet. In accordance with the aspectsof the disclosed embodiment, shipping cases for case units (e.g.cartons, barrels, boxes, crates, jugs, or any other suitable device forholding case units) may have variable sizes and may be used to hold caseunits in shipping and may be configured so they are capable of beingpalletized for shipping. It is noted that when, for example, bundles orpallets of case units arrive at the storage and retrieval system thecontent of each pallet may be uniform (e.g. each pallet holds apredetermined number of the same item—one pallet holds soup and anotherpallet holds cereal) and as pallets leave the storage and retrievalsystem the pallets may contain any suitable number and combination ofdifferent case units (e.g. a mixed pallet where each mixed pallet holdsdifferent types of case units—a pallet holds a combination of soup andcereal) that are provided to, for example the palletizer in a sortedarrangement for forming the mixed pallet. In the embodiments the storageand retrieval system described herein may be applied to any environmentin which case units are stored and retrieved.

Also referring to FIG. 1D, it is noted that when, for example, incomingbundles or pallets (e.g. from manufacturers or suppliers of case unitsarrive at the storage and retrieval system for replenishment of theautomated storage and retrieval system 100, the content of each palletmay be uniform (e.g. each pallet holds a predetermined number of thesame item—one pallet holds soup and another pallet holds cereal). As maybe realized, the cases of such pallet load may be substantially similaror in other words, homogenous cases (e.g. similar dimensions), and mayhave the same SKU (otherwise, as noted before the pallets may be“rainbow” pallets having layers formed of homogeneous cases). As palletsPAL leave the storage and retrieval system 100, with cases fillingreplenishment orders, the pallets PAL may contain any suitable numberand combination of different case units CU (e.g. each pallet may holddifferent types of case units—a pallet holds a combination of cannedsoup, cereal, beverage packs, cosmetics and household cleaners). Thecases combined onto a single pallet may have different dimensions and/ordifferent SKU's. In the exemplary embodiment, the storage and retrievalsystem 100 may be configured to generally include an in-feed section, astorage and sortation section and an output section as will be describedin greater detail below. As may be realized, in one aspect of thedisclosed embodiment the system 100 operating for example as a retaildistribution center may serve to receive uniform pallet loads of cases,breakdown the pallet goods or disassociate the cases from the uniformpallet loads into independent case units handled individually by thesystem, retrieve and sort the different cases sought by each order intocorresponding groups, and transport and assemble the correspondinggroups of cases into what may be referred to as mixed case pallet loadsMPL. As may also be realized, as illustrated in FIG. 15, in one aspectof the disclosed embodiment the system 100 operating for example as aretail distribution center may serve to receive uniform pallet loads ofcases, breakdown the pallet goods or disassociate the cases from theuniform pallet loads into independent case units handled individually bythe system, retrieve and sort the different cases sought by each orderinto corresponding groups, and transport and sequence the correspondinggroups of cases (in the manner described herein) at an operator station160EP where items are picked from the different case units CU, and/orthe different case units CU themselves, are placed in a bag, tote orother suitable container TOT by an operator 1500, or any suitableautomation, to fulfill a customer order according to, for example, anorder in which the case units CU are sequenced at the operator station160EP, noting that the sequencing of the case units CU as describedherein effects the sequencing of the case units CU at the operatorstation 160EP.

The in-feed section may generally be capable of resolving the uniformpallet loads to individual cases, and transporting the cases viasuitable transport, for input to the storage and sortation section. Thestorage and sortation section in turn may receive individual cases,store them in a storage area and retrieve desired cases individually inaccordance with commands generated in accordance to orders entered intoa warehouse management system for transport to the output section. Thesorting and grouping of cases according to order (e.g. an order outsequence) may be performed in whole or in part by either the storage andretrieval section or the output section, or both, the boundary betweenbeing one of convenience for the description and the sorting andgrouping being capable of being performed any number of ways. Theintended result is that the output section assembles the appropriategroup of ordered cases, that may be different in SKU, dimensions, etc.into, in one aspect, mixed case pallet loads in the manner described in,for example, U.S. patent application Ser. No. 13/654,293 filed on Oct.17, 2012 the disclosure of which is incorporated herein by reference inits entirety, while in other aspects the output section assembles theappropriate group of ordered case units, that may be different in SKU,dimensions, etc. into bags, totes or other suitable containers tofulfill a customer order at the operator station 160EP.

In one aspect of the exemplary embodiment, the output section generatesthe pallet load in what may be referred to as a structured architectureof mixed case stacks. The structured architecture of the pallet load maybe characterized as having several flat case layers L121-L125, L12T, atleast one of which is formed of non-intersecting, free-standing andstable stacks of multiple mixed cases. The mixed case stacks of thegiven layer have substantially the same height, to form as may berealized substantially flat top and bottom surfaces of the given layer,and may be sufficient in number to cover the pallet area, or a desiredportion of the pallet area. Overlaying layer(s) may be orientated sothat corresponding cases of the layer(s) bridge between the stacks ofthe supporting layer. Thus, stabilizing the stacks and correspondinglythe interfacing layer(s) of the pallet load. In defining the pallet loadinto a structured layer architecture, the coupled 3-D pallet loadsolution is resolved into two parts that may be saved separately, avertical (1-D) part resolving the load into layers, and a horizontal(2-D) part of efficiently distributing stacks of equal height to fillout the pallet height of each layer. In other aspects the load fill ofmixed cases may be configured in any other suitable ordered sequence andmay be loaded on or in any suitable transport device such as, forexample, a bag, tote, shopping carriage, a truck or other suitablecontainer fill without palletization. As will be described below, in oneaspect, the storage and retrieval system outputs case units to theoutput section so that the two parts of the 3-D pallet load solution areresolved, while in other aspects the storage and retrieval systemoutputs case units to the output section according to a sequence forfilling non-palletized customer orders at the operator station 160EP.

In accordance with aspects of the disclosed embodiment the automatedstorage and retrieval system 100 includes input stations 160IN (whichinclude depalletizers 160PA and/or conveyors 160CA for transportingitems to lift modules for entry into storage) and output stations 160UT(which include palletizers 160PB, operator stations 160EP, and/orconveyors 160CB for transporting case units from lift modules forremoval from storage), input and output vertical lift modules 150A, 150B(generally referred to as lift modules 150—it is noted that while inputand output lift modules are shown, a single lift module may be used toboth input and remove case units from the storage structure), a storagestructure 130, and a number of autonomous rovers or transport vehicles110 (referred to herein as “bots”). As used herein the lift modules 150,storage structure 130 and bots 110 may be collectively referred toherein as the storage and sorting section noted above. It is also notedthat the depalletizers 160PA may be configured to remove case units frompallets so that the input station 160IN can transport the items to thelift modules 150 for input into the storage structure 130. Thepalletizers 160PB may be configured to place items removed from thestorage structure 130 on pallets PAL for shipping.

Also referring to FIG. 1C, the storage structure 130 may includemultiple storage rack modules RM, configured in a three dimensionalarray RMA, that are accessible by storage or deck levels 130L. Eachstorage level 130L includes storage spaces 130S formed by the rackmodules RM where the rack modules include shelves that are disposedalong storage or picking aisles 130A which, e.g., extend linearlythrough the rack module array RMA and provide access to the storagespaces 130S and transfer deck(s) 130B over which the bots 110 travel ona respective storage level 130L for transferring case units between anyof the storage spaces 130S of the storage structure 130 (e.g. on thelevel which the bot 110 is located) and any of the lift modules 150(e.g. each of the bots 110 has access to each storage space 130S on arespective level and each lift module 150 on a respective storage level130L). The transfer decks 130B are arranged at different levels(corresponding to each level 130L of the storage and retrieval system)that may be stacked one over the other or horizontally offset, such ashaving one transfer deck 130B at one end or side of the storage rackarray RMAE1 or at several ends or sides RMAE1, RMAE2 of the storage rackarray as described in, for example, U.S. patent application Ser. No.13/326,674 filed on Dec. 15, 2011 the disclosure of which isincorporated herein by reference in its entirety.

The transfer decks 130B are substantially open and configured for theundeterministic traversal of bots 110 across and along the transferdecks 130B. As may be realized, the transfer deck(s) 130B at eachstorage level 130L communicate with each of the picking aisles 130A onthe respective storage level 130L. Bots 110 bi-directionally traversebetween the transfer deck(s) 130B and picking aisles 130A on eachrespective storage level 130L to access the storage spaces 130S disposedin the rack shelves alongside each of the picking aisles 130A (e.g. bots110 may access storage spaces 130S distributed on both sides of eachaisle such that the bot 110 may have a different facing, as will bedescribed in greater detail below, when traversing each picking aisle130A). As noted above, the transfer deck(s) 130B also provide bot 110access to each of the lifts 150 on the respective storage level 130Lwhere the lifts 150 feed and remove case units to and/or from eachstorage level 130L where the bots 110 effect case unit transfer betweenthe lifts 150 and the storage spaces 130S. Each storage level 130L mayalso include charging stations 130C for charging an on-board powersupply of the bots 110 on that storage level 130L such as described in,for example, U.S. patent application Ser. No. 14/209,086 filed on Mar.13, 2014 and Ser. No. 13/326,823 filed on Dec. 15, 2011 the disclosuresof which are incorporated herein by reference in their entireties.

The bots 110 may be any suitable independently operable autonomoustransport vehicles that carry and transfer case units throughout thestorage and retrieval system 100. In one aspect the bots 110 areautomated, independent (e.g. free riding) autonomous transport vehicles.Suitable examples of bots can be found in, for exemplary purposes only,U.S. patent application Ser. No. 13/326,674 filed on Dec. 15, 2011; U.S.patent application Ser. No. 12/757,312 filed on Apr. 9, 2010; U.S.patent application Ser. No. 13/326,423 filed on Dec. 15, 2011; U.S.patent application Ser. No. 13/326,447 filed on Dec. 15, 2011; U.S.patent application Ser. No. 13/326,505 Dec. 15, 2011; U.S. patentapplication Ser. No. 13/327,040 filed on Dec. 15, 2011; U.S. patentapplication Ser. No. 13/326,952 filed on Dec. 15, 2011; U.S. patentapplication Ser. No. 13/326,993 filed on Dec. 15, 2011; U.S. patentapplication Ser. No. 14/486,008 filed on Sep. 15, 2014; and U.S.provisional patent application No. 62/107,135, entitled “Storage andRetrieval System Transport Vehicle” filed on Jan. 23, 2015, thedisclosures of which are incorporated by reference herein in theirentireties. The bots 110 may be configured to place case units, such asthe above described retail merchandise, into picking stock in the one ormore levels of the storage structure 130 and then selectively retrieveordered case units.

The bots 110, lift modules 150 and other suitable features of thestorage and retrieval system 100 are controlled by, for example, one ormore central system control computers (e.g. control server) 120 through,for example, any suitable network 180. In one aspect the network 180 isa wired network, a wireless network or a combination of wireless andwired networks using any suitable type and/or number of communicationprotocols. In one aspect, the control server 120 includes a collectionof substantially concurrently running programs (e.g. system managementsoftware) for substantially automatic control of the automated storageand retrieval system 100. The collection of substantially concurrentlyrunning programs, for example, being configured to manage the storageand retrieval system 100 including, for exemplary purposes only,controlling, scheduling, and monitoring the activities of all activesystem components, managing inventory (e.g. which case units are inputand removed, the order in which the cases are removed and where the caseunits are stored) and pickfaces PF (see FIG. 6, e.g. one or more caseunits that are movable as a unit and handled as a unit by components ofthe storage and retrieval system), and interfacing with a warehousemanagement system 2500. For simplicity and ease of explanation the term“case unit(s)” is generally used herein for referring to both individualcase units and pickfaces (e.g. more than one case that is moved orotherwise handled as a unit).

Referring also to FIGS. 1A and 1B the rack module array RMA of thestorage structure 130 includes vertical support members 1212 andhorizontal support members 1200 that define a high density automatedstorage array as will be described in greater detail below. Rails 1200Smay be mounted to one or more of the vertical and horizontal supportmembers 1212, 1200 in, for example, picking aisles 130A and beconfigured so that the bots 110 ride along the rails 1200S through thepicking aisles 130A. At least one side of at least one of the pickingaisles 130A of at least one storage level 130L may have one or morestorage shelves (e.g. formed by rails 1210, 1200 and slats 1210S)provided at differing heights so as to form multiple shelf levels130LS1-130LS4 between the storage or deck levels 130L defined by thetransfer decks 130B. Accordingly, there are multiple rack shelf levels130LS1-130LS4, corresponding to each storage level 130L, extending alongone or more picking aisles 130A communicating with the transfer deck130B of the respective storage level 130L. As may be realized, themultiple rack shelf levels 130LS1-130LS4 effect each storage level 130Lhaving stacks of stored case units (or case layers) that are accessiblefrom a common deck 1200S of a respective storage level 130L (e.g. thestacks of stored cases are located between storage levels).

As may be realized, bots 110 traversing a picking aisle 130A, at acorresponding storage level 130L, have access (e.g. for picking andplacing case units) to each storage space 130S that is available on eachshelf level 130LS1-130LS4, where each shelf level 130LS1-130LS4 islocated between the storage levels 130L on one or more side PAS1, PAS2(FIG. 1C) of the picking aisle 130A. As noted above, each of the storageshelf levels 130LS1-130LS4 is accessible by the bot 110 from the rails1200S (e.g. from a common picking aisle deck 1200S that corresponds witha transfer deck 130B on a respective storage level 130L). As can be seenin FIGS. 1A and 1B there are one or more shelf rails 1210 verticallyspaced (e.g. in the Z direction) from one another to form multiplestacked storage spaces 130S each being accessible by the bot 110 fromthe common rails 1200S. As may be realized, the horizontal supportmembers 1200 also form shelf rails (in addition to shelf rails 1210) onwhich case units are placed.

Each shelf level 130LS1-130LS4 defines an open and undeterministic twodimensional storage surface (e.g. having a case unit support plane CUSPas shown in FIG. 1B) that facilitates a dynamic allocation of pickfacesboth longitudinally (i.e. along a length the aisle or coincident with apath of bot travel defined by the picking aisle) and laterally (i.e.transverse to the aisle or the path of bot travel). Dynamic allocationof the pickfaces and case units that make up the pickfaces is provided,for example, in the manner described in U.S. Pat. No. 8,594,835 issuedon Nov. 26, 2013, the disclosure of which is incorporated by referenceherein in its entirety. As such, case unit (or tote) pickfaces ofvariable lengths and widths are positioned at each two dimensionalstorage location on the storage shelves (e.g. on each storage shelflevel 130LS1-130LS4) with minimum gaps (e.g. that effect picking/placingof case units free from contact with other case units stored on theshelves) between adjacent stored case units/storage spaces.

In one aspect of the disclosed embodiment a vertical pitch between rackshelf levels 130LS1-130LS4 (that correspond to each storage level 130L)is varied so that a height Z1A-Z1E between the shelves is different,rather than equal. In other aspects, as shown in FIG. 1E, the verticalpitch P1 between at least some of the rack shelves is the same so thatthe height Z1A-Z1E between at least some shelves is equal while thevertical pitch P3 between other shelves is different. In still otheraspects, as can be seen in FIG. 1E, the pitch of rack shelf levels130LS1-130LS4 on one storage level 130L2 is a constant pitch P1 (e.g.the rack shelf levels are substantially equally spaced in the Zdirection) while the pitch of rack shelf levels 130LS1-130LS4 on adifferent storage level 130L1 have a different constant pitch P2.

In one aspect, the storage space(s) 130S defined by the storage shelflevels 130LS1-130LS4 between the storage or deck levels 130Laccommodates case units of different heights, lengths, widths and/orweights at the different shelf levels 130LS1-130LS4. For example,referring to FIGS. 1F and 3 the storage level 130L includes storagesections having at least one intermediate shelf. In the example shown,one storage section includes one intermediate shelf 1210A while anotherstorage section includes two intermediate shelves 1210B, 1210C forforming shelf levels 130LS1-130LS4. In one aspect the pitch Z1 betweenstorage levels 130L is any suitable pitch such as, for example, about 32inches to about 34 inches while in other aspects the pitch is more thanabout 34 inches and/or less than about 32 inches. Any suitable number ofshelves may be provided between the decks 1200S of adjacent verticallystacked storage levels 130L where the shelves have the same or differingpitches between the shelves (see e.g. FIG. 3 where case units CUD1,CUD2, CUE1-CUE3, CUF1, CUF2 are located in a vertical stack on one sideof the picking aisle and case units CUA, CUB, CUC are located in avertical stack on an opposite side of the picking aisle on storageshelves having a substantially similar pitch). For example, stillreferring to FIG. 1F, one section of the storage level 130L includes twostorage shelves where one shelf has a pitch of Z1A and the other shelfhas a pitch of Z1B where Z1A and Z1B are different from each other. Thisdiffering pitch allows for the placement of case units CUD, CUE havingdiffering heights Z5, Z6 in a stack one above the other on a commonstorage level 130L. In other aspects pitches Z1A, Z1B may besubstantially the same. In this aspect the storage level 130L includesanother storage section that has three storage shelves where one shelfhas a pitch of Z2, one storage shelf has a pitch of Z3 and the otherstorage shelf has a pitch of Z4 where Z2, Z3 and Z4 are different fromeach other. In other aspects at least two of the pitches Z2, Z3 and Z4are substantially the same. In one aspect the pitch between the shelvesis arranged so that larger and/or heavier case units CUC, CUE arearranged closer to the deck 1200S than smaller and/or lighter case unitsCUD, CUA, CUB. In other aspects the pitch between the shelves isarranged so that the case units are arranged in any suitable positionsthat may or may not be related to case unit size and weight.

In one aspect of the disclosed embodiment the storage or deck levels130L (e.g. the surface on which the bots 110 travel) are arranged at anysuitable predetermined pitch Z1 that is not, for example, an integermultiple of the intermediate shelf pitch(es) Z1A-Z1E. In other aspectsthe pitch Z1 may be an integer multiple of the intermediate shelf pitch,such as for example, the shelf pitch may be substantially equal to thepitch Z1 so that the corresponding storage space has a heightsubstantially equal to the pitch Z1. As may be realized, the shelf pitchZ1A-Z1E is substantially decoupled from the storage level pitch 130L andcorresponds to general case unit heights Z2-Z6 as illustrated in FIG.1F. In one aspect of the disclosed embodiment case units of differentheights are dynamically allocated or otherwise distributed along eachaisle within a storage space 130S having a shelf height commensuratewith the case unit height. The remaining space between the storagelevels 130L, both along the length of the aisle coincident with thestored case unit (e.g. in the X direction) and alongside the stored caseunit, being freely usable for dynamic allocation for cases of acorresponding height. As may be realized, the dynamic allocation of caseunits having different heights onto shelves having different pitchesprovides for stored case layers of different heights, between storagelevels 130L on both sides of each picking aisle 130A, with each caseunit being dynamically distributed along a common picking aisle 130A sothat each case unit within each stored case layer being independentlyaccessible (e.g. for picking/placing) by the bot in the common aisle.This placement/allocation of case units and the arrangement of thestorage shelves provides maximum efficiency of storage space/volume usebetween the storage levels 130L, and hence of maximum efficiency of therack module array RMA, with optimized distribution of case unit SKU's aseach aisle length may include multiple case units of different heights,yet each rack shelf at least shelf level may be filled by dynamicallocation/distribution (e.g. to fill the three dimensional rack modulearray RMA space in length, width and height, to provide a high densitystorage array).

In one aspect of the disclosed embodiment, still referring to FIG. 1F,the rack shelves 1210A-1210C (inclusive of the rack shelf formed by rail1200) are sectioned SECA, SECB longitudinally (e.g. along the length ofthe picking aisle 130A in the X direction, with respect to a storagestructure frame of reference REF2) to form ordered or otherwise matchedrack shelf sections along each picking aisle 130A. The aisle shelfsections SECA, SECB are ordered/matched to each other based on, forexample, a pick sequence of a bot 110 traversing the aisle in a commonpass picking case units destined for a common order fill (e.g. based onthe order out sequence). In other words, a bot 110 makes a single pass(e.g. traversal in a single direction) down a single or common pickingaisle while picking one or more case units from aisle shelf sectionsSECA, SECB on a common side of the picking aisle 130A to build apickface on the bot 110 where the pickface includes case units that arearranged on the bot according to the order fill/order out sequence aswill be described in greater detail below. Each of the aisle racksections SECA, SECB includes intermediate shelves in the mannerdescribed above. In other aspects some of the aisle shelves do notinclude intermediate shelves while others do include intermediateshelves.

In one aspect, the ordered aisle rack sections SECA, SECB include shelfpitches that are different between sections SECA, SECB. For example, ascan be seen in FIG. 1F aisle rack section SECA has shelves with pitchesZ1C-Z1E while aisle rack section SECB has shelves with pitches Z1B, Z1A.In accordance with the aspects of the disclosed embodiment, the pitchZ1A-Z1E of at least one intermediate shelf 1210A-1210C of one aisle racksection SECA, SECB is related to the pitch Z1A-Z1E of at least oneintermediate shelf 1210A-1210C of another of the ordered aisle racksections SECA, SECB of the common picking aisle 130A. The differentpitches Z1A-Z1E of the intermediate shelves 1210A-1210C in the orderedaisle rack section SECA, SECB are selected so as to be related and toeffect multiple (at least two) ordered picks (i.e. picks in an orderedsequence) with a bot 110, in accordance with a mixed SKU load outsequence (e.g. palletizing to a common pallet load), from shelves ofdifferent pitches, from a common pass of a common picking aisle 130A. Asmay be realized, the mixed load output from the storage and retrievalsystem 100 (e.g. to fill a truck loadport/pallet load) is sequenced in apredetermined order according to various load out picking aisles (e.g.aisles from which case units are picked for transfer to an outgoingpallet) and the shelf pitch in the ordered sections SECA, SECBfacilitate a bot 110 pick of more than one case unit in ordered sequenceaccording to an order of the load out sequence in a common picking aislepass (e.g. more than one case unit is picked in a predetermined orderfrom a common picking aisle in one pass of the common picking aisle).The different aisle shelf pitches Z1A-Z1E of the ordered rack sectionsSECA, SECB are so related to increase the probability of such an orderedmulti-pick (the picking of two or more case units from a single aislewith a single pass of the aisle as described above) so that themulti-pick is performed by each bot order fulfillment pass along eachaisle, and so related such that more than a majority of cases picked inthe storage and retrieval system 100 by the bots 110 and destined for acommon load out (e.g. a common pallet load) are picked by a common bot110 in an ordered sequence corresponding to the load out sequence duringa single pass of a common picking aisle (e.g. the two or more casespicked by the bot 110 are picked from the same picking aisle in a singlepass, e.g. the bot travels in a single direction once through thepicking aisle). As may be realized, in one aspect of the disclosedembodiment both sides PAS1, PAS2 (FIG. 1C) of the picking aisle 130Ahave ordered aisle rack sections SECA-SECH where one ordered section maybe matched with one or more sections on the same side PAS1, PAS2 of thecommon picking aisle 130A. As may be realized, the matched aisle racksections may be located adjacent one another or spaced apart from oneanother along the picking aisle 130A.

Referring now to FIGS. 2 and 3, as noted above, the bot 110 includes atransfer arm 110PA that effects the picking and placement of case unitsfrom the stacked storage spaces 130S defined at least in part, in the Zdirection) by the rails 1210A-1210C, 1200 (e.g. where the storage spacesmay be further defined in the X and Y directions through the dynamicallocation of the case units as described above). The bots 110, as notedabove, transport case units between each lift module 150 and eachstorage space 130S on a respective storage level 130L. The bots 110include a frame 110F having a drive section 110DR and a payload section110PL. The drive section 110DR includes one or more drive wheel motorseach connected to a respective drive wheel(s) 202. In this aspect thebot 110 includes two drive wheels 202 located on opposite sides of thebot 110 at end 110E1 (e.g. first longitudinal end) of the bot 110 forsupporting the bot 110 on a suitable drive surface however, in otheraspects any suitable number of drive wheels are provided on the bot 110.In one aspect each drive wheel 202 is independently controlled so thatthe bot 110 may be steered through a differential rotation of the drivewheels 202 while in other aspects the rotation of the drive wheels 202may be coupled so as to rotate at substantially the same speed. Anysuitable wheels 201 are mounted to the frame on opposite sides of thebot 110 at end 110E2 (e.g. second longitudinal end) of the bot 110 forsupporting the bot 110 on the drive surface. In one aspect the wheels201 are caster wheels that freely rotate allowing the bot 110 to pivotthrough differential rotation of the drive wheels 202 for changing atravel direction of the bot 110. In other aspects the wheels 201 aresteerable wheels that turn under control of, for example, a botcontroller 110C (which is configured to effect control of the bot 110 asdescribed herein) for changing a travel direction of the bot 110. In oneaspect the bot 110 includes one or more guide wheels 110GW located at,for example, one or more corners of the frame 110F. The guide wheels110GW may interface with the storage structure 130, such as guide rails(not shown) within the picking aisles 130A, on the transfer deck 130Band/or at transfer stations for interfacing with the lift modules 150for guiding the bot 110 and/or positioning the bot 110 a predetermineddistance from a location to/from which one or more case units are placedand/or picked up as described in, for example, U.S. patent applicationSer. No. 13/326,423 filed on Dec. 15, 2011 the disclosure of which isincorporated herein by reference in its entirety. As noted above, thebots 110 may enter the picking aisles 130A having different facingdirections for accessing storage spaces 130S located on both sides ofthe picking aisles 130A. For example, the bot 110 may enter a pickingaisle 130A with end 110E2 leading the direction of travel or the bot mayenter the picking aisle 130A with end 110E1 leading the direction oftravel.

The payload section 110PL of the bot 110 includes a payload bed 110PB, afence or datum member 110PF, a transfer arm 110PA and a pusher bar ormember 110PR. In one aspect the payload bed 110PB includes one or morerollers 110RL that are transversely mounted (e.g. relative to alongitudinal axis LX of the bot 110) to the frame 110F so that one ormore case units carried within the payload section 110PL can belongitudinally moved (e.g. justified with respect to a predeterminedlocation of the frame/payload section and/or a datum reference of one ormore case units) along the longitudinal axis of the bot, e.g., toposition the case unit at a predetermined position within the payloadsection 110PL and/or relative to other case units within the payloadsection 110PL (e.g. longitudinal forward/aft justification of caseunits). In one aspect the rollers 110RL may be driven (e.g. rotatedabout their respective axes) by any suitable motor for moving the caseunits within the payload section 110PL. In other aspects the bot 110includes one or more longitudinally movable pusher bar (not shown) forpushing the case units over the rollers 110RL for moving the caseunit(s) to the predetermined position within the payload section 110PL.The longitudinally movable pusher bar may be substantially similar tothat described in, for example, U.S. patent application Ser. No.13/326,952 filed on Dec. 15, 2011, the disclosure of which waspreviously incorporated by reference herein in its entirety. The pusherbar 110PR is movable in the Y direction, relative to the bot 110reference frame REF to effect, along with the fence 110PF and or pickhead 270 of the transfer arm 110PA, a lateral justification of caseunit(s) within the payload area 110PL in the manner described in U.S.provisional patent application No. 62/107,135, entitled “Storage andRetrieval System Transport Vehicle” filed on Jan. 23, 2015, previouslyincorporated herein by reference in its entirety.

Still referring to FIG. 2, the case units are placed on the payload bed110PB and removed from the payload bed 110PB with the transfer arm110PA. The transfer arm 110PA includes a lift mechanism or unit 200located substantially within the payload section 110PL as described in,for example, U.S. provisional patent application No. 62/107,135,entitled “Storage and Retrieval System Transport Vehicle” filed on Jan.23, 2015, previously incorporated herein by reference in its entirety.The lift mechanism 200 provides both gross and fine positioning ofpickfaces carried by the bot 110 which are to be lifted vertically intoposition in the storage structure 130 for picking and/or placing thepickfaces and/or individual case units to the storage spaces 130S (e.g.on a respective storage level 130L on which the bot 110 is located). Forexample, the lift mechanism 200 provides for picking and placing caseunits at the multiple elevated storage shelf levels 130LS1-130LS4accessible from the common picking aisle deck 1200S (see e.g. FIGS. 1Aand 3 and as described above).

The lift mechanism 200 is configured so that combined robot axis movesare performed (e.g. combined substantially simultaneous movement of thepusher bar 110PR, lift mechanism 200, pick head extension and fore/aftjustification mechanism(s) such as, e.g., the longitudinally movablepusher bar described above), so that different/multi-sku or multi-pickpayloads are handled by the bot. In one aspect, the actuation of thelifting mechanism 200 is independent of actuation of the pusher bar110PR as will be described below. The decoupling of the lift mechanism200 and pusher bar 110PR axes provides for combined pick/place sequenceseffecting a decreased pick/place cycle time, increased storage andretrieval system throughput and/or increased storage density of thestorage and retrieval system as described above. For example, the liftmechanism 200 provides for picking and placing case units at multipleelevated storage shelf levels accessible from a common picking aisledeck as described above.

The lifting mechanism may be configured in any suitable manner so that apick head 270 of the bot 110 bi-directionally moves along the Z axis(e.g. reciprocates in the Z direction—see FIG. 2). In one aspect, thelifting mechanism includes a mast 200M and the pick head 270 is movablymounted to the mast 200M in any suitable manner. The mast is movablymounted to the frame in any suitable manner so as to be movable alongthe lateral axis LT (e.g. in the Y direction) of the bot 110. In oneaspect the frame includes guide rails 210A, 210B to which the mast 200is slidably mounted. A transfer arm drive 250A, 250B may be mounted tothe frame for effecting at least movement of the transfer arm 110PAalong the lateral axis LT (e.g. Y axis) and the Z axis. Referring toFIGS. 2, 2A and 3, in one aspect the transfer arm drive 250A, 250Bincludes an extension motor 301 and a lift motor 302. The extensionmotor 301 may be mounted to the frame 110F and coupled to the mast 200Min any suitable manner such as by a belt and pulley transmission 260A, ascrew drive transmission (not shown) and/or a gear drive transmission(not shown). The lift motor 302 may be mounted to the mast 200M andcoupled to pick head 270 by any suitable transmission, such as by a beltand pulley transmission 271, a screw drive transmission (not shown)and/or a gear drive transmission (not shown). As an example, the mast200M includes guides, such as guide rails 280A, 280B, along which thepick head 270 is mounted for guided movement in the Z direction alongthe guide rails 280A, 280B. In other aspects the pick head is mounted tothe mast in any suitable manner for guided movement in the Z direction.With respect to the transmissions 271, a belt 271B of the belt andpulley transmission 271 is fixedly coupled to the pick head 270 so thatas the belt 271 moves (e.g. is driven by the motor 302) the pick head270 moves with the belt 271 and is bi-directionally driven along theguide rails 280A, 280B in the Z direction. As may be realized, where ascrew drive is employed to drive the pick head 270 in the Z direction, anut may be mounted to the pick head 270 so that as a screw is turned bythe motor 302 engagement between the nut and screw causes movement ofthe pick head 270. Similarly, where a gear drive transmission isemployed a rack and pinion or any other suitable gear drive may drivethe pick head 270 in the Z direction. In other aspects any suitablelinear actuators are used to move the pick head in the Z direction. Thetransmission 260A for the extension motor 301 is substantially similarto that described herein with respect to transmission 271.

Still referring to FIG. 2 the pick head 270 of the bot 110 transferscase units between the bot 110 and a case unit pick/place location suchas, for example, the storage spaces 130S and/or interface shelves7000A-7000L of lift interface/transfer stations LTS (see FIG. 10)between the bot 110 and a lift module(s) 150. In one aspect, the pickhead 270 includes a base member 272, one or more tines or fingers273A-273E and one or more actuators 274A, 274B. The base member 272 ismounted to the mast 200M, as described above, so as to ride along theguide rails 280A, 280B. The one or more tines 273A-273E are mounted tothe base member 272 at a proximate end of the tines 273A-273E so that adistal end of the tines 273A-273E (e.g. a free end) is cantilevered fromthe base member 272. Referring again to FIG. 1B, the tines 273A-273E areconfigured for insertion between slats 1210S that form the case unitsupport plane CUSP of the storage shelves.

One or more of the tines 273A-273E is movably mounted to the base member272 (such as on a slide/guide rail similar to that described above) soas to be movable in the Z direction. In one aspect any number of tinesare mounted to the base member 272 while in the aspect illustrated inthe figures there are, for example, five tines 273A-273E mounted to thebase member 272. Any number of the tines 273A-273E are movably mountedto the base member 272 while in the aspect illustrated in the figures,for example, the outermost (with respect to a centerline CL of the pickhead 270) tines 273A, 273E are movably mounted to the base member 272while the remaining tines 273B-273D are immovable relative to the basemember 272.

In this aspect the pick head 270 employs as few as three tines 273B-273Dto transfer smaller sized case units (and/or groups of case units) toand from the bot 110 and as many as five tines 273A-273E to transferlarger sized case units (and/or groups of case units) to and from thebot 110. In other aspects, less than three tines are employed (e.g. suchas where more than two tines are movably mounted to the base member 272)to transfer smaller sized case units. For example, in one aspect all butone tine 273A-273E is movably mounted to the base member so that thesmallest case unit being transferred to and from the bot 110 withoutdisturbing other case units on, for example, the storage shelves has awidth of about the distance X1 between slats 1210S (see FIG. 1B).

The immovable tines 373B-373D are used when transferring all sizes ofcase units (and/or pickfaces) while the movable tines 373A, 373E areselectively raised and lowered (e.g. in the Z direction with theactuators 274A, 274B) relative to the immovable tines 373B-373D totransfer larger case units (and/or pickfaces). Still referring to FIG. 2an example is shown where all of the tines 273A-273E are positioned sothat a case unit support surface SF of each tine 273A-273E is coincidentwith a picking plane SP (FIG. 4) of the pick head 270. As may berealized, in other aspects the two end tines 273A, 273E are positionedlower (e.g. in the Z direction) relative to the other tines 273B-273D sothat the case unit support surface SF of tines 273A, 273E is offset from(e.g. below) the picking plane SP so that the tines 273A, 273E do notcontact the one or more case units carried by the pick head 270 and donot interfere with any unpicked case units positioned in storage spaces130S on the storage shelves or any other suitable case unit holdinglocation.

The movement of the tines 273A-273E in the Z direction is effected bythe one or more actuators 274A, 274B mounted at any suitable location ofthe transfer arm 110PA. In one aspect, the one or more actuators 274A,274B are mounted to the base member 272 of the pick head 270. The one ormore actuators are any suitable actuators, such as linear actuators,capable of moving one or more tines 273A-273E in the Z direction. In theaspect illustrated in, for example, FIG. 2 there is one actuator 274A,274B for each of the movable tines 273A, 273E so that each moveable tineis independently movable in the Z direction. In other aspects oneactuator may be coupled to more than one movable tine so that the morethan one movable tine move as a unit in the Z direction.

As may be realized, movably mounting one or more tines 273A-273E on thebase member 272 of the pick head 270 provides for full support of largecase units and/or pickfaces on the pick head 270 while also providingthe ability to pick and place small case units without interfering withother case units positioned on, for example, the storage shelves. Theability to pick and place variably sized case units without interferingwith other case units on the storage shelves reduces a size of a gap GP(see FIG. 1A) between case units on the storage shelves. As may berealized, because the tines 273B-273D are fixed to the base member 272there is no duplicative motion when picking/placing case units as thelifting and lowering of case units and/or pickfaces to and from the caseunit holding location is effected solely by the lift motor 301, 301A.

Referring again to FIG. 2, it is again noted that the pusher bar 110PRis movable independent of the transfer arm 110PA. The pusher bar 110PRis movably mounted to the frame in any suitable manner such as by, forexample, a guide rod and slide arrangement and is actuated along the Ydirection (e.g. in a direction substantially parallel to theextension/retraction direction of the transfer arm 110PA). In one aspectat least one guide rod 360 is mounted within the payload section 110PLso as to extend transversely relative to the longitudinal axis LX of theframe 110F. The pusher bar 110PR may include at least one slide member360S configured to engage and slide along a respective guide rod 360. Inone aspect, at least the guide rod/slide arrangement holds the pusherbar 110PR captive within the payload section 110PL. The pusher bar 110PRis actuated by any suitable motor and transmission, such as by motor 303and transmission 303T. In one aspect the motor 303 is a rotary motor andthe transmission 303T is a belt and pulley transmission. In otheraspects the pusher bar 110PR may be actuated by a linear actuator havingsubstantially no rotary components.

The pusher bar 110PR is arranged within the payload section 110PL so asto be substantially perpendicular to the rollers 110RL and so that thepusher bar 110PR does not interfere with the pick head 270. As can beseen in FIG. 6, the bot 110 is in a transport configuration where atleast one case unit would be supported on the rollers 110RL (e.g. therollers collectively form the payload bed). In the transportconfiguration the tines 273A-273E of the pick head 270 areinterdigitated with the rollers 110RL and are located below (along the Zdirection) a case unit support plane RSP (see FIG. 4) of the rollers110RL. The pusher bar 110PR is configured with slots 351 (FIG. 7) intowhich the tines 273A-273E pass where sufficient clearance is providedwithin the slots 351 to allow the tines to move below the case unitsupport plane RSP and to allow free movement of the pusher bar 110PRwithout interference from the tines 273A-273E. The pusher bar 110PR alsoincludes one or more apertures through which the rollers 110RL passwhere the apertures are sized to allow free rotation of the rollersabout their respective axes. As may be realized, the independentlyoperable pusher bar 110PR does not interfere with the rollers 110PR,extension of the transfer arm 110PA in the transverse direction (e.g. Ydirection) and the lifting/lowering of the pick head 270.

As noted above, because the pusher bar 110PR is a separate, standaloneaxis of the bot 110 that operates free of interference from the pickhead 270 extension and lift axes, the pusher bar 110PR can be operatedsubstantially simultaneously with the lifting and/or extension of thetransfer arm 110PA. The combined axis moves (e.g. the simultaneousmovement of the pusher bar 110PR with the transfer arm 110PA extensionand/or lift axes) provides for increased payload handling throughput andeffects the ordered (e.g. according to the predetermined load outsequence) multi-pick of two or more case units from a common pickingaisle, in one common pass of the picking aisle. For example, referringto FIGS. 4-5, during a transfer arm 110PA multi-pick/place sequence thepusher bar 110PR is prepositioned (as the case unit(s) and/or pickfaceare being picked and transferred into the payload section 110PL) to alocation that is a predetermined distance X2 away from the contact depthX3 (e.g. the depth of the tines occupied by the case unit(s) and/orpickface CU when being picked/placed from a storage space or other caseunit holding location) (FIG. 11, Block 1100). The distance X2 is aminimized distance that only allows sufficient clearance between pusherbar 110PR and the case unit(s) to allow the case unit(s) to be seated onthe rollers 110RL. As the case unit(s) CU are lowered onto the rollers110RL (FIG. 11, Block 1110) the distance travelled by the pusher bar110PR to contact the case unit(s) CU is a shorter distance X2 whencompared to moving from a back side 402 (relative to the lateraldirection and an access side 401 of the payload section 110PL) of thepayload section 110PL a distance X4 as with conventional transportvehicles. When the case unit(s) CU are lowered by the transfer arm 110PAand transferred to the rollers 110RL so as to be solely supported by therollers 110RL, the pusher bar 110PR is actuated to forward (relative tothe lateral direction and an access side 401 of the payload section110PL) justify the case unit(s) CU (FIG. 11, Block 1120). For example,the pusher bar 110PB may push the case unit(s) CU laterally in the Ydirection so that the case unit(s) contact the fence 110PF (which islocated at the access side 401 of the payload section 110PL so that acase unit reference datum may be formed through contact between the caseunit(s) CU and the fence 110PF. In one aspect the pusher bar 110PR mayengage or otherwise grip the case unit(s) CU during transport of thecase units (e.g. so as to hold the case unit(s) against the fence 110PF)for maintaining the case unit(s) CU in a predetermined spatialrelationship with each other and a reference frame REF (FIG. 2) of thebot 110 (FIG. 11, Block 1130). When placing the case unit(s) the pusherbar 110PR, after justifying the case unit(s) CU against the fence 110PF,is withdrawn (e.g. in the Y direction) from contact with the caseunit(s) CU (FIG. 11, Block 1140). Substantially immediately after thepusher bar 110PR disengages the case unit(s) CU one or more of the liftaxis (e.g. in the Z direction) and extension axis (e.g. in the Ydirection) of the transfer arm 110PA are actuated substantiallysimultaneously with the withdrawing movement of the pusher bar 110PR(FIG. 11, Block 1150). In one aspect both the lift and extension axesare actuated when the pusher bar is withdrawn from contact with the caseunit(s) CU while in other aspect one of the lift and extension axes isactuated. As may be realized, the simultaneous movement of the transferarm 110PA lift axis and/or extension axis with the withdrawal of thepusher bar 110PR as well as the decreased distance the pusher moves tojustify the case unit(s) CU decreases the time needed to transfer caseunit(s) CU to and from the bot 110 and increases throughput of thestorage and retrieval system 100.

In another aspect of the disclosed embodiment, as may be realized, inthe multi-pick/place sequence multiple case units are substantiallysimultaneously carried and manipulated within the payload section 110PLto further increase throughput of the storage and retrieval system 100and to effect the multi-pick/place sequence in accordance with apredetermined order out sequence. Referring also to FIG. 1C, the botreceives pick and place commands from, for example, control server 120(and/or warehouse management system 2500) and the bot controller 110Cexecutes those commands for forming the ordered multi-pick. Here the bot110 enters the common aisle 130A1 from, for example, the transfer deck130B for making a single or common pass through the picking aisle 130A1during which the bot 110 picks two or more case units according to thepredetermined order out sequence (FIG. 12, Block 1201A). In one aspectthe manipulation of the case units CU is a sorting of the case units (inother words picking and placing of case units according to thepredetermined load out sequence) where the cases are positioned on thetransfer arm 110PA for picking/placement of the case units and/orpositioned so that the case units are not transferred and remain on thetransfer arm 110PA while other case units are transferred to and fromthe transfer arm 110PA. Here, the bot 110 travels through the commonpicking aisle 130A1 in the direction of arrow XC and stops at apredetermined storage space 130S1, according to the predetermined orderout sequence, where the bot 110 picks one or more case units from thepredetermined storage space 130S1 with a common transfer arm 110PA whereplacement of the case units on the common transfer arm 110PA correspondsto the predetermined order out sequence as will be described in greaterdetail below (e.g. the case units are sorted on-the-fly, e.g. duringtransport, with the bot 110).

As an example of case manipulation on the bot 110, referring also toFIGS. 6-9, case unit(s) CUA may be picked from a case unit holdinglocation (e.g. such as storage spaces 130S in a common picking aisle foreffecting the ordered multi-pick, and in other aspects from a lifttransfer station LTS, see FIG. 1C, and/or a case unit buffer stationlocated in a picking aisle or on the transfer deck) and transferred intothe payload section 110PL (FIG. 12, Block 1201B). As the case unit(s)CUA is being transferred into the payload section 110PL the pusher bar110PR may be pre-positioned (FIG. 12, Block 1204) adjacent the fence110PF so that the pusher bar 110PR is positioned between the caseunit(s) CUA and the fence 110PF when the case unit(s) CUA is lowered fortransfer to the rollers 110RL (FIG. 12, Block 1205). The pusher bar110PR is actuated to push the case unit(s) CUA (resting on the rollers110RL) in the Y direction towards the back (e.g. rear) 402 of thepayload section 110PL so that the case unit(s) CUA contacts ajustification surface 273JS (FIG. 4) of the tines 273A-273E and isjustified to the back 402 of the payload section 110PL (FIG. 12, Block1210).

In one aspect, the bot 110 continues to traverse the common pickingaisle 130A1 in the same direction XC (e.g. so that all of the case unitsin the ordered multi-pick are picked in the common pass of the pickingaisle with the bot 110 travelling in a single direction) and stops atanother predetermined storage space 130S according to the predeterminedorder out sequence. As noted above, the pusher bar 110PR remains incontact with (e.g. grips) the case unit(s) CUA during transport of thecase unit(s) between case unit holding locations so that the caseunit(s) CUA remains in a predetermined location at the back 402 of thepayload section 110PL (and/or at a predetermined locationlongitudinally) relative to the reference frame REF of the bot 110 (FIG.12, Block 1215). To pick subsequent case units, from for example, theother storage space 130S2 of the common picking aisle 130A1 the pusherbar 110PR is moved in the Y direction to disengage the case unit(s) CUAand the lift and extension axes of the transfer arm 110PA are actuatedto retrieve another case unit(s) CUB from the other storage space 130S2(or in other aspects from e.g. a lift transfer station LTS and/or abuffer station as noted above) (FIG. 12, Block 1220). While the caseunit(s) CUB are being picked the pusher bar 110PR is positioned in the Ydirection adjacent the back 402 of the payload section 110PL so as to belocated between the case units CUA and the justification surface 273JSof the tines 273A-273E (FIG. 12, Block 1225). The case unit(s) CUB aretransferred into the payload section and lowered/placed on the rollers110RL (FIG. 12, Block 1230) so that the case units CUA, CUB are arrangedrelative to each other along the Y axis. The pusher bar 110PR isactuated in the Y direction to push the case units CUA, CUB towards thefence 110PF to forward justify the case units CUA, CUB (FIG. 12, Block1234) and grip/hold the case units CUA, CUB for transport (FIG. 12,Block 1235). As may be realized, in one aspect the case units CUA, CUBare placed at a case unit holding location together as a unit while inother aspects the case units CUA, CUB are sorted, e.g. transported toand placed at separate positions of a common case unit holding locationor at different case unit holding locations (FIG. 12, Block 1240) aswill be described in greater detail below. For example, referring alsoto FIG. 10, the bot 110 carrying the ordered multi-pick payloadtransfers the case units of the ordered multi-pick to one or moretransfer stations LTS (which include buffer shelves 7000A-7000L) ofoutput lifts 150B1, 150B2. Where the case units of the multi-pick areplaced at different positions of, for example, a common buffer ortransfer shelf 7000A-7000L or a transfer station LTS of the lifts 150B1,150B2 the bot 110 places a first one of the case units CUB(corresponding to, for exemplary purposes pickface 7 in FIG. 10 which inthis example includes a single case unit) in a first position of thebuffer shelf 7000B and places the second one of the case units CUA(corresponding to, for exemplary purposes pickface 5 in FIG. 10 which inthis example includes a single case unit) in a second position of thebuffer shelf 7000B. Where the case units of the multi-pick are placed ata common case unit holding location the bot 110 places both case unitsCUA, CUB as a unit at for example, a common position of buffer shelf7000A (corresponding to, for exemplary purposes pickface 9 in FIG. 10which in this example, includes two case units)

Where the case units CUA, CUB are sorted (FIG. 12, Block 1250) forplacement at separate positions of a common case holding location or atdifferent case holding locations, the case units CUA, CUB are separatedfrom each other in the payload section 110PL. For example, the pick head270 of the transfer arm 110PA may be moved in the Z direction to liftthe case units CUA, CUB from the rollers 110RL by an amount sufficientto allow the pusher bar 110PR to pass beneath the case unit(s) (FIG. 13,Block 1250A). As the case units CUA, CUB are lifted the pusher bar 110PRis positioned along the Y direction so as to be located between the caseunits CUA, CUB (see FIG. 9) (FIG. 13, Block 1250B). The pick head 270 islowered so that the case units CUA, CUB are transferred to the rollers110RL and so that the pusher bar is inserted between the case units CUA,CUB (FIG. 13, Block 1250C). The pusher bar 110PR is moved in the Ydirection (e.g. to separate the case unit(s)) to move case unit(s) CUAtowards the back 402 of the payload section 110PL (e.g. against thejustification surface 273JS of the tines 273A-273E or any other suitableposition) while the case unit(s) CUB remain at the front of the payloadsection 110PL adjacent the fence 110PF (e.g. as shown in FIG. 7) (FIG.13, Block 1250D). As may be realized, where the case units are heldagainst the justification surface 273JS of the tines during transport,the pusher bar is moved in the Y direction (e.g. to separate the caseunit(s)) to move case unit(s) CUB towards the front 401 of the payloadsection 110PL (e.g. against the fence 110PF or any other suitableposition) while the case unit(s) CUA remain at the back of the payloadsection 110PL adjacent the justification surface 273JS. The pusher bar110PR may also be moved in the Y direction to re-justify the caseunit(s) CUB against the fence 110PF to position the case unit(s) on thetines 273A-273E for placement at a case unit holding location (FIG. 13,Block 1250E). As may be realized, with the case unit(s) CUA beingpositioned substantially against the justification surface 273JS of thetines 273A-273E (e.g. of the pick head 270) the case unit(s) CUB can beplaced at a case unit holding location substantially withoutinterference from the case unit(s) CUA (FIG. 13, Block 1250F), e.g. thecase unit CUA is free from contacting case units disposed at the caseunit holding location. The case unit(s) CUA is lowered/transferred backinto the payload section 110PL (e.g. by retracting and lowering thetransfer arm 110PA) (FIG. 13, Block 1250G). The pusher bar 110PR, whichis pre-positioned between the justification surface 273JS and the caseunit(s) CUA, pushes the case unit(s) CUA, which is disposed on therollers 110RL, against the fence 110PF to forward justify the caseunit(s) CUA for placement at another case unit holding location (e.g.different than the holding location that case unit(s) CUB were placed)(FIG. 13, Block 1250H). The pusher bar 110PR remains against the caseunit(s) CUA for gripping (e.g. with the fence) the case unit(s) duringtransport to the other case unit holding location (FIG. 13, Block1250I). The pusher bar 110PR moves away from the case unit(s) CUA andthe transfer arm is actuated to lift and extend the pick head 270 forplacing the case unit(s) CUA at the other case unit holding location(FIG. 13, Block 1250J).

An example of a case unit(s) multi-pick and place operation with on thefly sortation of the case units for creating a mixed pallet load MPL (asshown in FIG. 1D) and/or to fill a customer order bag, tote or othercontainer TOT at an operator station 160EP (as shown in FIG. 15)according to a predetermined order out sequence will be described withrespect to FIG. 1C in accordance with an aspect of the disclosedembodiment. For example, assuming customer orders require case unit(s) 7to be delivered to output lift 150B1 and case units 5 to also bedelivered to output lift 150B1 (in other aspects, it is noted thatcustomer orders may require case units carried by a common bot 110 to bedelivered to different output lifts 150B1, 150B2 such that the transferof the case units carried by the common bot 110 to different outputlifts occurs in a manner substantially similar to that describedherein), the bot 110 enters picking aisle 130A1 and picks case unit 7from storage space 130S1 in the manner described above with respect toFIGS. 11-13 (FIG. 14, Block 1400). The case unit(s) 7 is justified onthe bot 110 towards the rear of the payload section 110PL as describedabove (FIG. 14, Block 1405). The bot 110 continues to travel through thepicking aisle 130A1 in a common pass of the picking aisle and picks caseunit 5 from a different storage space 130S2 with the common transfer arm110PA so that both case unit(s) 7, 5 are located adjacent one another onthe common transfer arm 110PA (FIG. 14, Block 1410). In other aspectsboth case units 7, 5 are picked as a unit by the common transfer arm110PA from a common storage space 130S3, such as from picking aisle130A2 (FIG. 14, Block 1415). As may be realized, in one aspect, thecontroller 110C is configured to effect picking of the case unit(s) inan order that is opposite an order in which the case unit(s) are placed.

In this multi-pick example, the case unit holding location(s) correspondto storage spaces 130S of the picking aisles 130 but in other aspectsthe case unit holding location(s) include input lift modules 150A1,150A2 (where a direct transfer between bots and the lift occurs),transfer or buffer stations LTS for interfacing with the input liftmodules 150A1, 150A2, (where an indirect transfer between the liftmodules and the bots occurs) and storage spaces 130S1-130S4 (pickingfrom the transfer stations LTS and the input lift modules with the botis noted where case units are needed for a predetermined order outsequence are not located in the storage spaces 130S but are being inputinto the storage rack array in a just in time manner to be deliveredsubstantially directly to the output lift(s) 150B1, 150B2.

The bot 110 grips both case units 7, 5 within the payload section 110PLin the manner described above and exits the picking aisle 130A1 (FIG.14, Block 1420). The bot travels along the transfer deck 130B andinterfaces with output lift 150B1 (FIG. 14, Block 1421). The botseparates the case units 7, 5 within the payload section 110PL, asdescribed above, so that case unit(s) 5 is justified towards the frontof the payload section 110PL and case unit(s) 7 is justified towards theback of the payload section 110PL (FIG. 14, Block 1425). The case unit 5is transferred to the output lift 150B1 directly by the bot 110 (e.g.the pick head 270 of the bot interfaces directly with a shelf of thelift) or indirectly such as through the transfer/buffer station LTSshelf 7000B (the case unit is transferred to the station LTS and thestation interfaces with the shelf of the lift) (FIG. 14, Block 1430).The bot retracts the transfer arm 110PA to return the case unit(s) 7 tothe payload section 110PL (FIG. 14, Block 1435) and grips the case unitCUC (FIG. 14, Block 1420). The case unit(s) CUC is transported to asecond position of output lift 150B1 (FIG. 14, Block 1421), justifiedtoward the front of the payload section 110PL (FIG. 14, Block 1425), asdescribed above, and transferred to output lift 150B1 either directly orindirectly, as described above (FIG. 14, Block 1430). In other aspects,depending on the predetermined case unit output sequence, the bot 110places both case unit(s) 7, 5 at a common location/position, such as atone of output lifts 150B1, 150B2. For example, pickface 20 on shelf7000H comprises both case units 7, 5 such that the bot 110 places bothcase units as a multi-case unit pickface at a single position of shelf7000H.

The output lifts 150B1, 150B2 transfer the ordered multi-pick(s) placedon the shelves 7000A-7000L by the bots 110 to the output station 160UTalso in accordance with the predetermined order out sequence. Forexample, still referring to FIG. 10, the pickfaces 1-22 are picked bythe lifts 150B1, 150B2 in sequenced order so that the pickfaces 1-22 aredelivered to the output station 160UT in the predetermined order neededto form the mixed pallet load MPL and/or to fill a customer order bag,tote or other container TOT at an operator station 160EP.

Referring to FIG. 16, in accordance with aspects of the disclosedembodiment, in a method for filling orders, storage spaces are arrayedon racks along picking aisles (FIG. 16, Block 1600). Multiple leveldecks are also provided (FIG. 16, Block 1610), where at least one decklevel of the multiple level decks communicates with each aisle, wherethe multiple level decks and aisles define a rolling surface for anautonomous transport vehicle at each level of the multiple level decks.Racks at multiple rack levels are accessed from a respective rollingsurface that is common to the multiple rack levels (FIG. 16, Block1620), where the racks are disposed along at least one aisle at eachlevel of the multiple level decks. In one aspect, a vertical pitchbetween rack levels varies for a portion of a respective aisle. In oneaspect, the vertical pitch between at least two rack levels of theportion of the respective aisle is related to another vertical pitchbetween at least two other rack levels of another aisle portion of therespective aisle so that the autonomous transport vehicle effectsmultiple picks in an ordered sequence in a common aisle pass. In oneaspect, the vertical pitch between at least two rack levels of theportion of the respective aisle is related to another vertical pitchbetween at least two other rack levels of another aisle portion of therespective aisle so that the vertical pitch and the other vertical pitcheffects substantially filling a vertical space between the multiple decklevels with stored items.

In accordance with one or more aspects of the disclosed embodiment, astorage array in an automated storage and retrieval system includesstorage spaces arrayed on racks along picking aisles; multiple leveldecks, where at least one deck level of the multiple level deckscommunicates with each aisle, where the multiple level decks and aislesare configured to define a rolling surface for an autonomous transportvehicle at each level of the multiple level decks, racks along at leastone aisle at each level of the multiple level decks are at multiple racklevels that are accessed from a respective rolling surface that iscommon to the multiple rack levels, and a vertical pitch between racklevels varies for a portion of a respective aisle; wherein the verticalpitch between at least two rack levels of the portion of the respectiveaisle is related to another vertical pitch between at least two otherrack levels of another aisle portion of the respective aisle so that theautonomous transport vehicle effects multiple picks in an orderedsequence in a common aisle pass.

In accordance with one or more aspects of the disclosed embodiment, theautonomous transport vehicle effects multiple picks of mixed cases inthe common aisle pass.

In accordance with one or more aspects of the disclosed embodiment, themultiple deck levels are disposed on both ends of the picking aisles.

In accordance with one or more aspects of the disclosed embodiment, aportion of the rolling surface defined by the multiple level decks isconfigured for undeterministic traverse the autonomous transport vehicleacross and along the rolling surface.

In accordance with one or more aspects of the disclosed embodiment, thestorage array further includes one or more vertical lifts incommunication with at least one of the multiple level decks, the one ormore vertical lifts being configured to, at least in part, transferstored items to and from the storage spaces.

In accordance with one or more aspects of the disclosed embodiment, eachof the multiple rack levels define an open and undeterministic storagesurface facilitating a dynamic allocation of pickfaces at each of themultiple rack levels.

In accordance with one or more aspects of the disclosed embodiment, themultiple level decks are arranged at a pitch that is not an integermultiple of the vertical pitch of the rack levels.

In accordance with one or more aspects of the disclosed embodiment, astorage array in an automated storage and retrieval system includesstorage spaces arrayed on racks along picking aisles; multiple leveldecks, where at least one level deck of the multiple level deckscommunicates with each aisle, where the multiple level decks and aislesare configured to define a rolling surface for an autonomous transportvehicle at each level of the multiple deck levels, racks along at leastone aisle at each level of the multiple level decks are at multiple racklevels that are accessed from a respective rolling surface that iscommon to the multiple rack levels, and a vertical pitch between racklevels varies for a portion of a respective aisle; wherein the verticalpitch between at least two rack levels of the portion of the respectiveaisle is related to another vertical pitch between at least two otherrack levels of another aisle portion of the respective aisle so that thevertical pitch and the other vertical pitch effects substantiallyfilling a vertical space between the multiple deck levels with storeditems.

In accordance with one or more aspects of the disclosed embodiment, themultiple deck levels are disposed on both ends of the picking aisles.

In accordance with one or more aspects of the disclosed embodiment, aportion of the rolling surface defined by the multiple level decks isconfigured for undeterministic traverse the autonomous transport vehicleacross and along the rolling surface.

In accordance with one or more aspects of the disclosed embodiment, thestorage array further includes one or more vertical lifts incommunication with at least one of the multiple level decks, the one ormore vertical lifts being configured to, at least in part, transferstored items to and from the storage spaces.

In accordance with one or more aspects of the disclosed embodiment, eachof the multiple rack levels define an open and undeterministic storagesurface facilitating a dynamic allocation of pickfaces at each of themultiple rack levels.

In accordance with one or more aspects of the disclosed embodiment, themultiple level decks are arranged at a pitch that is not an integermultiple of the vertical pitch of the rack levels.

In accordance with one or more aspects of the disclosed embodiment, amethod for filling an order includes providing storage spaces arrayed onracks along picking aisles; providing multiple level decks, where atleast one deck level of the multiple level decks communicates with eachaisle, where the multiple level decks and aisles define a rollingsurface for an autonomous transport vehicle at each level of themultiple level decks; and accessing racks at multiple rack levels, anddisposed along at least one aisle at each level of the multiple leveldecks, from a respective rolling surface that is common to the multiplerack levels, where a vertical pitch between rack levels varies for aportion of a respective aisle; wherein the vertical pitch between atleast two rack levels of the portion of the respective aisle is relatedto another vertical pitch between at least two other rack levels ofanother aisle portion of the respective aisle so that the autonomoustransport vehicle effects multiple picks in an ordered sequence in acommon aisle pass.

In accordance with one or more aspects of the disclosed embodiment, themethod further includes effecting multiple picks of mixed cases in thecommon aisle pass with the autonomous transport vehicle.

In accordance with one or more aspects of the disclosed embodiment, themethod further includes providing one or more vertical lifts incommunication with at least one of the multiple level decks; andtransferring, at least in part, stored items to and from the storagespaces with the one or more vertical lifts.

In accordance with one or more aspects of the disclosed embodiment, themethod further includes defining, with each of the multiple rack levels,an open and undeterministic storage surface facilitating a dynamicallocation of pickfaces at each of the multiple rack levels.

In accordance with one or more aspects of the disclosed embodiment, amethod for filling an order includes providing storage spaces arrayed onracks along picking aisles; providing multiple level decks, where atleast one level deck of the multiple level decks communicates with eachaisle, where the multiple level decks and aisles provide a rollingsurface for an autonomous transport vehicle at each level of themultiple deck levels; and accessing racks at multiple rack levels, anddisposed along at least one aisle at each level of the multiple leveldecks, from a respective rolling surface that is common to the multiplerack levels, where a vertical pitch between rack levels varies for aportion of a respective aisle; wherein the vertical pitch between atleast two rack levels of the portion of the respective aisle is relatedto another vertical pitch between at least two other rack levels ofanother aisle portion of the respective aisle so that the vertical pitchand the other vertical pitch effects substantially filling a verticalspace between the multiple deck levels with stored items.

In accordance with one or more aspects of the disclosed embodiment, themethod further includes providing one or more vertical lifts incommunication with at least one of the multiple level decks; andtransferring, at least in part, stored items to and from the storagespaces with the one or more vertical lifts.

In accordance with one or more aspects of the disclosed embodiment, themethod further includes defining, with each of the multiple rack levels,an open and undeterministic storage surface facilitating a dynamicallocation of pickfaces at each of the multiple rack levels.

It should be understood that the foregoing description is onlyillustrative of the aspects of the disclosed embodiment. Variousalternatives and modifications can be devised by those skilled in theart without departing from the aspects of the disclosed embodiment.Accordingly, the aspects of the disclosed embodiment are intended toembrace all such alternatives, modifications and variances that fallwithin the scope of the appended claims. Further, the mere fact thatdifferent features are recited in mutually different dependent orindependent claims does not indicate that a combination of thesefeatures cannot be advantageously used, such a combination remainingwithin the scope of the aspects of the invention.

What is claimed is:
 1. A storage array in an automated storage andretrieval system, the storage array comprising: stacked picking aisles,each of the stacked picking aisles being disposed at stacked aislelevels; storage spaces arrayed on racks along the stacked pickingaisles; at least one deck in communication with each of the stackedpicking aisles, where the at least one deck and at least one of thestacked picking aisles are configured to define a transport surface foran autonomous transport at each level of the at least one deck, theracks along the at least one picking aisle at each level of the at leastone deck are at multiple rack levels that are accessed from a respectivetransport surface that is common to the multiple rack levels, and avertical pitch between rack levels varies for a portion of a respectivepicking aisle; wherein the vertical pitch between at least two racklevels of the portion of the respective picking aisle is matched toanother vertical pitch between at least two other rack levels of anotherpicking aisle portion of the respective picking aisle based on apredetermined order pick criteria for effecting multiple picks with theautonomous transport in an ordered sequence.
 2. The storage array ofclaim 1, wherein the multiple picks with the autonomous transport in anordered sequence are in a common pass of one or more respective pickingaisle on a common level of the at least one deck.
 3. The storage arrayof claim 1, wherein the autonomous transport effects multiple picks ofmixed cases in the common pass of one or more respective picking aisle.4. The storage array of claim 1, wherein the at least one deck isdisposed on both ends of the picking aisles.
 5. The storage array ofclaim 1, wherein a portion of the transport surface defined by the atleast one deck is configured for undeterministic traverse of theautonomous transport across and along the transport surface.
 6. Thestorage array of claim 1, further comprising one or more vertical liftsin communication with the at least one deck, the one or more verticallifts being configured to, at least in part, transfer stored items toand from the storage spaces.
 7. The storage array of claim 1, whereineach of the multiple rack levels define an open and undeterministicstorage surface facilitating a dynamic allocation of pickfaces at eachof the multiple rack levels.
 8. The storage array of claim 1, whereinthe at least one deck includes multiple level decks that are arranged ata pitch that is not an integer multiple of the vertical pitch of therack levels.
 9. A storage array in an automated storage and retrievalsystem, the storage array comprising: stacked picking aisles disposed atstacked aisle levels; storage spaces arrayed on racks along each of thestacked picking aisles; at least one deck in communication with each ofthe stacked picking aisles on each aisle level, where the at least onedeck and at least one of the stacked picking aisles are configured todefine a transport surface for an autonomous transport at each level ofthe at least one deck, the racks along at least one picking aisle ateach level of the at least one deck are at multiple rack levels that areaccessed from a respective transport surface that is common to themultiple rack levels, and a vertical pitch between rack levels variesfor a portion of a respective picking aisle; wherein the vertical pitchbetween at least two rack levels of the portion of the respectivepicking aisle is matched to another vertical pitch between at least twoother rack levels of another picking aisle portion of one or morerespective picking aisle accessed from the common transport surface sothat the vertical pitch and the other vertical pitch effectssubstantially filling a vertical space of the stacked aisle levelsaccessed from the common transport surface with stored items.
 10. Thestorage array of claim 9, wherein the at least one deck is disposed onboth ends of the picking aisles.
 11. The storage array of claim 9,wherein a portion of the transport surface defined by the at least onedeck is configured for undeterministic traverse of the autonomoustransport across and along the transport surface.
 12. The storage arrayof claim 9, further comprising one or more vertical lifts incommunication with the at least one deck, the one or more vertical liftsbeing configured to, at least in part, transfer stored items to and fromthe storage spaces.
 13. The storage array of claim 9, wherein each ofthe multiple rack levels define an open and undeterministic storagesurface facilitating a dynamic allocation of pickfaces at each of themultiple rack levels.
 14. The storage array of claim 9, wherein the atleast one deck includes multiple level decks that are arranged at apitch that is not an integer multiple of the vertical pitch of the racklevels.
 15. A method for filling an order comprising: providing storagespaces arrayed on racks along stacked picking aisles, the stackedpicking aisles being disposed at stacked aisle levels; providing atleast one deck that communicates with each of the stacked picking aisleson each aisle level, where the at least one deck and at least one of thestacked picking aisles define a transport surface for an autonomoustransport at each level of the at least one deck; and accessing racks atmultiple rack levels, and disposed along the at least one of the stackedpicking aisles at level of the at least one deck, from a respectivetransport surface that is common to the multiple rack levels, where avertical pitch between rack levels varies for a portion of a respectiveone of the stacked picking aisles; wherein the vertical pitch between atleast two rack levels of the portion of the respective one of thestacked picking aisles is matched to another vertical pitch between atleast two other rack levels of another picking aisle portion of therespective one of the stacked picking aisles based on a predeterminedorder pick criteria for effecting multiple picks with the transport inan ordered sequence.
 16. The method of claim 15, wherein the multiplepicks with the autonomous transport in an ordered sequence are in acommon pass of one or more respective aisle on a common level of the atleast one deck.
 17. The method of claim 15, further comprising effectingmultiple picks of mixed cases in the common pass of one or morerespective aisle with the autonomous transport.
 18. The method of claim15, further comprising: providing one or more vertical lifts incommunication with the at least one deck; and transferring, at least inpart, stored items to and from the storage spaces with the one or morevertical lifts.
 19. The method of claim 15, further comprising defining,with each of the multiple rack levels, an open and undeterministicstorage surface facilitating a dynamic allocation of pickfaces at eachof the multiple rack levels.
 20. A method for filling an ordercomprising: providing storage spaces arrayed on racks along each stackedpicking aisles, the stacked picking aisles disposed at stacked aislelevels; providing at least one deck that communicates with each of thestacked picking aisles on each aisle level, where the at least one deckand the stacked picking aisles provide a transport surface for anautonomous transport at each level of the at least one deck; andaccessing racks at multiple rack levels, and disposed along at least oneof the stacked picking aisles at each level of the at least one deck,from a respective transport surface that is common to the multiple racklevels, where a vertical pitch between rack levels varies for a portionof a respective one of the stacked picking aisles; wherein the verticalpitch between at least two rack levels of the portion of the respectiveone of the stacked picking aisles is matched to another vertical pitchbetween at least two other rack levels of another aisle portion of oneor more respective one of the stacked picking aisles accessed from thecommon transport surface so that the vertical pitch and the othervertical pitch effects substantially filling a vertical space of thestacked aisle levels accessed from the common transport surface withstored items.
 21. The method of claim 20, further comprising: providingone or more vertical lifts in communication with the at least one deck;and transferring, at least in part, stored items to and from the storagespaces with the one or more vertical lifts.
 22. The method of claim 20,further comprising defining, with each of the multiple rack levels, anopen and undeterministic storage surface facilitating a dynamicallocation of pickfaces at each of the multiple rack levels.